Produce radiographic testing techniques for castings

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This standard identifies the competences you need to determine and specify the radiographic test techniques for cast products, in accordance with approved procedures.  Radiographic techniques are the chief working document, which control the practical application of the prescribed method of testing castings.  Using the customer radiographic requirements for the product to be tested, you will be expected to prepare the technique, covering preparation for testing, testing practice, resources required, safe working practices and restorative work required.  Your technique will be validated by others, before being released to the testing personnel.

Your responsibilities will require you to comply with organisational policy and procedures for the production of the radiographic technique. You will report any problems that you cannot personally resolve, or that are outside your permitted authority, to the relevant people. You will be expected to work with a minimum of supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you undertake.

Your underpinning knowledge will provide a good understanding of your work and will provide an informed approach to determining and specifying the radiographic technique requirements.  You will understand the principles and practices of the prescribed method of radiography, and have knowledge of the principles of the other common methods of Non Destructive Testing (NDT).  An appreciation of the advantages and limitations of each method, in particular flaw detection capability, will be important as will a knowledge of the influence of the casting materials used on the feasibility of testing castings.  A working knowledge of relevant cast product technology and processes is required, in particular that related to the incidence of manufacturing defects/flaws.  An understanding of the role of quality management and the monitoring of quality through the application of acceptance criteria will be required.

You will be aware of any health, safety and environmental requirements applicable to your area of responsibility. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace and to the environment.

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1. work safely at all times, complying with health and safety legislation,  regulations, directives and other relevant guidelines
2. follow relevant instructions and specifications for producing documentation
3. produce radiographic technique documentation that is clear, accurate and contains all relevant test data and information
4. produce radiographic technique documentation in a format that meets organisational and customer requirements
5. ensure that codes and other references used in the radiographic technique documentation follow agreed conventions and regulations/directives/standards
6. gain approval of the radiographic technique documentation from the appropriate people according to the agreed schedule
7. make changes needed to radiographic technique documentation within agreed control procedures
8. deal promptly and effectively with problems within your control and report those that cannot be solved
9. ensure that work records are completed, stored securely and available to others, as per organisational requirements
10. leave the work area in a safe condition on completion of the activities, as per organisational and legal requirements

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1. the specific safety precautions to be taken whilst carrying out the  activities (including any specific legislation, regulations or codes of practice relating to the activities, equipment or materials)
2. the health and safety requirements of the work area and the activities, and the responsibility these requirements place on you
3. the hazards associated with  the activities, and how to minimise them and reduce risks
4. the personal protective equipment and clothing (PPE) to be worn during the activities
5. the methods of non-destructive testing (to include liquid penetrant testing, magnetic particle inspection and ultrasonic testing)
6. the advantages and limitations of each method with respect to applications, sensitivity, flaw type location capabilities, flaw recognition, sizing and accuracy of measurements, and use for surface and volumetric testing
7. the principles of radiographic testing and the various methods of obtaining images (film, digital detectors) and how to select the correct media
8. how to obtain information on the radiographic technique requirements and the type of information that is available (customer order requirements and instructions, quality control requirements and the product specification)
9. the factors which will affect the technique parameters to be specified (material type, manufacturing process/technology used, type of defects/flaws expected, degree of accuracy required)
10. the types of defect/flaws that are detectable using the various detection methods
11. the level of defects/flaws that will be acceptable in, and their influence on performance of the cast components, materials or structures
12. how to identify the test objectives, parameters and the type of data that should be included in the radiographic technique
13. how to identify the acceptance criteria, and the product quality required to meet design/customer criteria
14. the development of the radiographic technique (to include both master documents and working instructions, along with their purpose, content and status)
15. how to prepare the radiographic technique (to include the structure, style, clarity and compliance with relevant standards/directives and regulations)
16. the process used in the organisation to validate the radiographic techniques
17. the control procedure for ensuring that the radiographic techniques are maintained up to date
18. the terminology used in NDT testing activities
19. principles and practice of quality management systems and the role of NDT within the quality system
20. how to record the radiographic technique and the format required by the organisation/customer
21. the problems that can occur when specifying radiographic techniques, and how they can be minimised
22. the sources of technical expertise on radiographic techniques to help resolve problems
23. the extent of your own responsibility and whom you should report to if you have problems that you cannot resolve
24. how to access, use and maintain information to comply with organisational requirements and legislation

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1. Produce casting radiographic testing technique documentation by carrying out all of the following activities:

   1. use the correct issue of company information
   2. check that all essential information and data needed to specify the radiographic technique is available
   3. adhere to health and safety regulations, systems and           procedures to realise a safe system of work
   4. ensure that technical performance, costs and timescales are considered when producing the radiographic technique
   5. record and store the radiographic technique documentation in the correct formats and in the appropriate company system

2. Include all of the following requirements in the casting radiographic testing techniques:

   1. radiation source requirements
   2. use of image quality indicators (IQIs)
   3. source-to-film/detector distance
   4. beam/product orientation
   5. exposure times
   6. image type (such as film or digital)
   7. use of intensifying screens

   8. areas of product to be tested and their identification

         plus four from the following:

   9. safety/environmental requirements
   10. objectives of the test
   11. meet specified timescales
   12. equipment and consumables
   13. acceptance criteria
   14. equipment settings and calibration
   15. personnel certification requirements
   16. test parameters
   17. references to applicable standards
   18. test procedure(s) and technique(s)                 
   19. health and safety requirements and safe practice
   20. preparation of test areas
   21. datum and reference marking of test areas           
   22. reporting/recording methods and procedures

3. Produce casting radiographic testing techniques that comply with one of the following quality and accuracy standards:

   1. current industry standards, codes of practice or other international standards
   2. company standards and requirements
   3. customer standards and requirements

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2

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2023

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Current

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Original

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Semta

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SEMMPF3-069

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Engineering and Manufacturing Technologies, Manufacturing Technologies, Process Operatives, Process, Plant and Machine Operatives

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3113

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Engineering; specifying; manufacturing; processing; analysing; interpreting; radiographic; casting; preparation; test results; procedures; IQI requirements; technique; non-destructive testing

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